Single-skid, factory-assembled
We pre-assemble and interconnect every component before shipment to minimize your on-site construction time. This approach brings the system to operational status faster than field-assembled alternatives.
EXTREMATE - Industrial decontamination unit
The pre-engineered, steam-operated continuous solution designed for rapid integration and reliable high-throughput decontamination
The patented EXTREMATE 1000 industrial decontamination unit brings the reliability and performance of a fully engineered continuous flow decontamination system to facilities that need fast integration, minimal footprint, and guaranteed treatment outcomes. Pre-assembled on a single compact skid and steam-operated, this unit arrives ready for utility connection. It eliminates on-site construction delays and complex commissioning, moving your facility quickly toward a fully operational decontamination solution.
- Capacity: Up to 4,200 gallons per day (16,000 l/day)
- Technology: Continuous
- Energy: Steam 5 barg – 100kg/h
- Effluent BSL: BSL1, BSL2, BSL3
Pre-engineered, standardized, and factory-assembled on a single compact skid. Ready for connection to utilities on arrival, minimal on-site construction time required.
Pre-engineered for fast, reliable integration
Deploying a new decontamination system in an existing production facility is rarely straightforward. In fact, space constraints, utility access, maintenance clearance, and construction timelines all create friction between project approval and an operational system. With this in mind, the EXTREMATE 1000 was specifically designed to minimize every one of these friction points.
To achieve this, all components, heat exchangers, pumping system, instrumentation, PLC and HMI cabinet, are factory-assembled and interconnected on a single compact skid before shipment. Consequently, nothing needs to be assembled, piped, or wired on site beyond the utility connections themselves. The result is a system that arrives ready for startup and installs in a fraction of the time of field-assembled equipment. Moreover, it begins delivering validated continuous decontamination from the moment utilities are connected.
In terms of dimensions, the compact single-skid format, 85″ x 43″ x 85″, fits easily into the tight utility spaces and plant rooms where these systems are commonly deployed. Furthermore, this design ensures a small footprint without compromising maintenance access or operator ergonomics. In short, every component is positioned for direct, unobstructed access, keeping maintenance turnaround fast and downtime short.
Validated decontamination at 135°C
The EXTREMATE 1000 treats effluent at a standard temperature of 135°C (275°F) with a holding time of 60 seconds, delivering a validated F0 of 25. As a result, this performance is sufficient for the decontamination of BSL1, BSL2, and BSL3 biological effluents under standard containment requirements. However, for facilities requiring a higher sterility assurance level, the holding time can be extended to 120 seconds at 180°C. This delivers a validated F0 of 50, which is equivalent to the most stringent thermal decontamination standards in current regulatory use.
Regarding intake, incoming effluent is accepted across a wide temperature range of 20°C to 40°C (68°F to 95°F). Indeed, this accommodates the full range of effluent temperatures typically generated in research and production environments without pre-conditioning requirements.
Key Highlights
F0 25 to F0 50 validated performance
Adjusting the holding time from 60 to 120 seconds at 135°C delivers validated decontamination efficacy from F0 25 to F0 50. This range meets all BSL1 to BSL3 treatment requirements.
Compact footprint with full maintenance access
Measuring 85" x 43" x 85", the EXTREMATE 1000 minimizes your floor space requirements. Its design provides direct ergonomic access to all components for rapid maintenance operations.
PLC and HMI included as standard
The standard automation package includes a dedicated PLC with an HMI interface, giving operators full visibility and control over every decontamination parameter in real time.
Wide inlet temperature range
Accepts effluent from 20°C to 40°C without pre-conditioning, accommodating the natural temperature variation of effluents from research and production processes.
Ready for utility connection on arrival
Pre-engineered and standardized for rapid integration, the EXTREMATE 1000 reduces on-site construction time to a minimum and is operational as soon as utilities are connected.
Decontamination cycle
- Standard treatment: 135°C (275°F) for 60 seconds – F0 25
- Extended treatment: 135°C (275°F) for 120 seconds – F0 50
- Inlet effluent temperature: 20°C to 40°C (68°F to 95°F)
- Continuous processing at 1,000 liters per hour (4.4 gpm)
- Nominal daily capacity: up to 16,000 liters (4,200 gallons) based on 16-hour operation
- Steam operated thermal treatment
- PLC-monitored cycle parameters throughout
Design
- Pre-engineered single-skid design – all components factory-assembled and interconnected
- Compact footprint: L: 85″ – W: 43″ – H: 85″
- Steam-operated continuous flow heating
- Ergonomic layout with direct maintenance access to all components
- PLC and HMI automation package included as standard
- Designed for minimum floor space and minimum installation height
- Ready for utility connection on site – reduced on-site construction time
Available options
Performance & Safety
Duplex Pumps Package For facilities requiring critical pumping continuity, the duplex pump package provides a fully redundant configuration. This setup prevents a single pump failure from halting the decontamination process or interrupting effluent treatment during peak operational periods.
Magnetic Pumps For applications involving aggressive or chemically active effluents, the magnetic pump option provides a hermetically sealed, sealless solution. This technology eliminates mechanical seal failure and removes any leakage risk in the effluent circuit.
Duplex Strainers Package The duplex strainer option maintains continuous particulate filtration of incoming effluent, eliminating the need for system shutdowns during cleaning or maintenance. When one strainer requires servicing, the system automatically diverts flow to the second, ensuring uninterrupted treatment at all times.
Cooling For installations requiring effluent cooling before discharge, an integrated cooling section brings the temperature down to your target level. This built-in feature eliminates the need for any additional infrastructure.
Chemical Tanks and Dosing Pumps For facilities requiring pH adjustment, neutralization, or chemical dosing, integrated tanks and pumps deliver controlled chemical addition. We build this automated capability directly into the EXTREMATE skid.
Connectivity & Traceability
Remote Connection This feature allows authorized personnel to monitor system status, review operational data, and manage the EXTREMATE 1000 remotely from anywhere in the facility or off-site. This capability provides essential value for multi-unit sites or facilities that house the decontamination system in restricted-access areas.
Advanced Certificate Package For facilities operating under GMP or other regulated quality frameworks, the advanced certificate package delivers the comprehensive documentation required for formal equipment qualification. By providing FAT and SAT protocols, calibration certificates, and material traceability, this package reduces the time to operational release in regulated environments.
Critical Spare Parts A curated kit of critical spare parts keeps essential components on hand at your facility. This ensures you can replace parts immediately during normal operations, minimizing lead time and downtime during unplanned maintenance.
Why Choose Actini?
At the industrial scale, decontamination failures do more than trigger compliance citations; they jeopardize production continuity, public health, and your facility’s operating license. To address this, Actini applies its engineering expertise and proven track record to prevent these risks from ever materializing.
Furthermore, with hundreds of large-scale systems operating in vaccine manufacturing facilities, government research campuses, and biotech sites across the US and worldwide, facilities trust Actini when they demand perfection. Ultimately, our ISO 14001 certification and “Made in the USA” manufacturing standards back our commitment.
Our products are designed, manufactured, and sold locally: in the United States for our U.S. customers, and in Canada for our Canadian customers.
Ready to deploy continuous decontamination without the integration overhead?
The EXTREMATE 1000 arrives pre-assembled, pre-tested, and ready to connect. This ensures your facility reaches validated, operational decontamination faster than any field-assembled alternative. Talk to our technical team today and find out how it fits into your production environment.